Construction insert

ABSTRACT

A construction insert configured for use within an elevator hoistway is provided. The construction insert includes a channel having a front face and a back face opposing the front face. The channel is configured to define an internal passage within the channel. A plurality of brackets is attached to the back face of the channel, each of the brackets configured for attachment to a structure within the elevator hoistway. Each of the brackets is planar in shape.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/223,092, filed Jul. 6, 2009, the disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates in general to the construction of structures, such as for example, commercial buildings. More specifically, this invention relates to construction devices that can be used for construction within an elevator hoistway.

Structures, such as commercial buildings, can be built using a variety of construction devices and methods. One example of a construction device is a construction insert. A construction insert can be used within an elevator hoistway and is attached to a hoistway structure, such as for example, a wall or a beam. After installation, subsequent devices, such as for example, wiring conduit, can be attached to the construction insert.

The design and configuration of construction inserts can vary according to the structure to which it is being attached. For example, a construction insert configured for attachment to a poured concrete hoistway wall can have a different design and configuration than a construction insert configured for attachment to a steel hoistway beam.

Additionally, construction inserts can include a channel, which is designed to trap a threaded nut. The subsequent devices attached to the construction insert are held by a bolt threaded into the trapped nut. The length of the bolt used depends on the device being attached to the construction insert. Accordingly, construction inserts require that the length of the bolt is carefully sized to provide a secure attachment of the subsequent devices to the construction insert.

It would be advantageous to provide a construction insert to accommodate the varying structures forming an elevator hoistway.

SUMMARY OF THE INVENTION

The above objects, as well as other objects not specifically enumerated, are achieved by a construction insert configured for use within an elevator hoistway. The construction insert includes a channel having a front face and a back face opposing the front face. The channel is configured to define an internal passage within the channel. A plurality of brackets is attached to the back face of the channel, each of the brackets configured for attachment to a structure within the elevator hoistway. Each of the brackets is planar in shape.

According to this invention there is also provided a construction insert configured for use within an elevator hoistway. The construction insert includes a channel having a slot extending continuously from a first end to a second end. The channel has a top face, a bottom face, a front face, and a back face configured to define an internal passage within the channel. A plurality of brackets is attached to the back face of the channel, each of the brackets is configured for attachment to a structure within the elevator hoistway. The internal passage formed within the channel is adapted to receive a head of a bolt, thereby constraining rotational movement of the bolt relative to the channel. Each of the brackets is planar in shape.

According to this invention there is also provided a construction insert in combination with a bolt, the combination configured for use within an elevator hoistway. The combination of the construction insert and the bolt includes a channel having a slot extending continuously from a first end to a second end. The channel has a top face, a bottom face, a front face, and a back face configured to define an internal passage within the channel. A plurality of brackets is attached to the back face of the channel. Each of the brackets is configured for attachment to a structure within the elevator hoistway. The internal passage formed within the channel is adapted to receive a head of the bolt, thereby constraining rotational movement of the bolt relative to the channel. Each of the brackets is planar in shape.

According to this invention there is also provided a method of securing an object within an elevator hoistway. The method includes the steps of providing a construction insert, the construction insert including a channel and a plurality of brackets, the channel having a slot extending continuously from a first end to a second end, the channel having a top face, a bottom face, a front face and a back face configured to define an internal passage within the channel, each of the brackets attached to the back face of the channel, wherein the internal passage formed within the channel is adapted to receive a head of a bolt, thereby constraining rotational movement of the bolt relative to the channel, and wherein the brackets are planar in shape, attaching each of the brackets of the construction insert to a structure within the elevator hoistway such that the front face of the construction insert is facing away from the structure, inserting a head of the bolt into the internal passage of the construction insert such that the bolt extends through the slot; and fastening the object to the bolt.

Various objects and advantages of the construction insert will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a construction insert configured for use within an elevator hoistway.

FIG. 2 is a side view in elevation of the construction insert illustrated in FIG. 1 showing a trapped bolt.

FIG. 3 is a perspective view of the construction insert illustrated in FIG. 1 illustrating attachment to a wall formed from poured concrete.

FIG. 4 is a perspective view of the construction insert illustrated in FIG. 1 illustrating attachment to a wall formed from concrete block.

FIG. 5 is a perspective view of the construction insert illustrated in FIG. 1 illustrating attachment to a steel hoistway beam.

FIG. 6 is a perspective view of the construction insert illustrated in FIG. 1 illustrating attachment to a wall formed from a wood framework and covered by drywall panels.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described with reference to the specific embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities of dimensions such as length, width, height, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

Referring now to the drawings, there is illustrated in FIG. 1 a construction insert, indicated generally at 10, configured for use within an elevator hoistway of a building. The term “elevator hoistway,” as used herein, is defined to mean a vertically-oriented space within a building, enclosed by walls and elevator doors, for the travel of one or more elevators, dumbwaiters, or material lifts.

Referring again to FIG. 1, as will be explained in more detail below, the construction insert 10 is configured for attachment to a structure within the hoistway, such as for example, a wall or a beam, and further configured as a fixture to which subsequent components, structures or devices can be fastened.

The construction insert 10 includes a channel 12 and spaced apart brackets 14 and 16. The channel 12 includes a front face 18, a back face 20, a top face 22, a bottom face 24, a first end 26 and a second end 28. The front face 18 includes a slot 30. In the illustrated embodiment, the slot 30 extends continuously from the first end 26 to the second end 28 of the channel 12. In other embodiments, the slot 30 can include discontinuous segments extending from the first end 26 to the second end 28. The front face 18, back face 20, top face 22 and bottom face 24 form an internal passage 32.

Referring again to FIG. 1, the construction insert 10 has a length L. In the illustrated embodiment, the length L is approximately 30.0 inches. However, in other embodiments, the length L can be more or less than approximately 30.0 inches.

In the embodiment illustrated in FIG. 1, the construction insert 10 is made of metallic material, such as the non-limiting example of steel, and is finished with a rust-preventative coating. In other embodiments, the construction insert 10 can be made from other materials or combinations of materials, including the non-limiting example of reinforced polymeric materials, and can have other desired finishes, platings or coatings, such as for example, a powder-coated finish. In still other embodiments, the construction insert 10 can be made of materials having no finish.

Referring again to FIG. 1, the brackets 14 and 16 are attached to the back face 20 of the channel 12. In the illustrated embodiment, the brackets 14 and 16 are attached to the back face 20 of the channel 12 by welding. However, the brackets 14 and 16 can be attached to the back face 20 of the channel 12 by other desired methods, including the non-limiting example of mechanical fasteners (not shown). In the illustrated embodiment, the brackets 14 and 16 extend in a generally perpendicular direction from a plane defined by the back face 20 of the channel 12. Alternatively, the brackets 14 and 16 can be configured to extend in a generally non-perpendicular direction from a plane defined by the back face 20 of the channel 12.

As shown in FIG. 1, the bracket 14 is spaced apart from the first end 26 by a distance D1, and the bracket 16 is spaced apart from the second end 28 by a distance D2. In the illustrated embodiment, the distances D1 and D2 are in a range of from about 2.0 inches to about 6.0 inches. Alternatively, the distances D1 and D2 can be less than about 2.0 inches or more than about 6.0 inches. While the embodiment shown in FIG. 1 illustrated the distances D1 and D2 to be approximately the same, it should be appreciated that in other embodiments, the distances D1 and D2 can be different from each other.

Referring now to FIGS. 1 and 2, the bracket 14 has a top face 15 a, a bottom face 15 b, and edges 17 a-17 c. Similarly, the bracket 16 has a top face 19 a, a bottom face (not shown), and edges 21 a-21 c. The illustrated brackets 14 and 16 are generally planar in shape, although such is not required.

Referring again to FIG. 1, the brackets 14 and 16 each include a first aperture 40 and a plurality of second apertures 42. Each of the first apertures 40 is configured for passage of a support rod, including the non-limiting examples of reinforcing bar (commonly called “rebar”) or threaded rod. In the illustrated embodiment, each of the first apertures 40 has a diameter in a range of from about 0.25 inches to about 1.5 inches. In other embodiments, the first apertures 40 can have diameters less than about 0.25 inches or more than about 1.5 inches.

In the illustrated embodiment, the second apertures 42 are spaced apart along the respective perimeters of the brackets 14 and 16 and are configured for passage of respective attachment devices, such as for example, nails. In other embodiments, the second apertures 42 can be spaced apart in any desired pattern. Any desired quantity of second apertures 42 can be used.

Referring now to FIG. 2, the internal passage 32, defined by the front face 18, back face 20, top face 22 and bottom face 24 of the channel 12, has a rectangular cross-sectional shape. Alternatively, the internal passage 32 can have other cross-sectional shapes. The rectangular cross-sectional shape of the internal passage 32 is configured to trap flats, 54 and 56, of a head 52 of a bolt 50 such that the bolt 50 is constrained from rotational movement relative to the channel 12. While the internal passage 32 is configured to prevent relative rotational movement of the bolt 50, the passage 32 is configured the bolt 50 is slidably movable along the length L of the slot 30.

In operation, a user inserts the head 52 of a bolt 50 into the passage 32 of the construction insert 10 and fastens an object to the bolt by attaching a nut (not shown) to the bolt 50. By trapping the head 52 of the bolt 50 within the passage 32, the construction insert 10 advantageously allows a user to install a bolt 50 having any desired approximate bolt length, without the requirement that the length of the bolt 50 be carefully sized.

Referring again to FIG. 2, the bolt 50 has a diameter DB. In the illustrated embodiment, the diameter DB of the bolt 50 is approximately 0.625 inches. In other embodiments, the diameter DB of the bolt 50 can be more or less than approximately 0.625 inches.

As shown in FIG. 2, the channel 12 has a height CH and a width CW. The height CH and width CW of the channel 12 are configured for several purposes. First, the height CH and width CW of the channel 12 are configured to provide a passage 32 having a size sufficient to trap the head 52 of the bolt 50, yet allow the head 52 of the bolt 50 to slide along the length L of the channel 12. Second, the height CH and width CW of the channel 12 are configured to provide the construction insert 10 with a low profile, thereby facilitating use of the construction insert 10 within the often cramped confines of an elevator hoistway. In the illustrated embodiment, the height CH is approximately 1.27 inches and the width CW is approximately 0.77 inches. However, the height CH and the width CW can be other desired dimensions.

Referring now to FIG. 3, the construction insert 10 is shown installed in a hoistway wall 60 formed from poured concrete. The construction insert 10 is installed in the wall 60 in the following manner. First, attachment devices (not shown) such as for example nails, are inserted through the small apertures 42 in the brackets 14 and 16 such that the construction insert 10 is attached to a concrete form (not shown). In this position, the front face 18 of the construction insert 10 is facing away from the concrete wall 60. Optional support rods 62 are positioned through the first aperture 40. The concrete forming the concrete wall 60 is poured, thereby fixing the construction insert 10 in place and the concrete wall 60 is allowed to cure. One or more bolts 50 are inserted into the channel 32 as described above. Various objects (not shown) can be attached to the construction insert 10. While the construction insert 10 is shown in a generally horizontal orientation, it should be appreciated that the construction insert 10 can have any desired orientation.

Referring now to FIG. 4, the construction insert 10 is shown installed in a hoistway wall 70 formed from a plurality of concrete blocks 71. The construction insert 10 is installed in the wall 70 in the following manner. First, the brackets 14 and 16 are located between adjacent concrete blocks 71 such that the large apertures 40 in the brackets 14 and 16 are positioned within void 72 between the concrete blocks 71. In this position, the front face 18 of the construction insert 10 is facing away from the hoistway wall 70. Optional support rods 62 are positioned through the large apertures 40. The void 72 between the concrete blocks 71 is filled with concrete 73, thereby fixing the construction insert 10 in place. The concrete 73 is allowed to cure. One or more bolts 50 are inserted into the channel 32 and the construction insert 10 can be used as described above.

Referring now to FIG. 5, the construction insert 10 is shown attached to a metallic beam 80 positioned with an elevator hoistway. While the beam 80 illustrated in FIG. 5 has the shape of an I-beam, it should be appreciated that in other embodiments, the construction insert 10 can be attached to other types of hoistway beams, including the non-limiting examples of T-shaped beams and angled beams. The construction insert 10 is installed to the hoistway beam 80 in the following manner. First, the brackets 14 and 16 are positioned to be flush with a beam flange surface 82 such that the front face 18 of the construction insert 10 is facing away from the hoistway beam 80. The brackets 14 and 16 then are attached to the beam surface 82. In certain embodiments, the brackets 14 and 16 can be attached to the beam 80 by welding. In other embodiments, the brackets 14 and 16 can be attached to the beam 80 by mechanical fasteners, such as for example, nuts and bolts. Once the construction insert 10 is attached to the beam 80, the construction insert 10 can be used as described above.

Referring now to FIG. 6, the construction insert 10 is shown installed to a hoistway wall 90 constructed from framework 92 and covered by drywall panels 94. In the illustrated embodiment, the framework 92 is made from wood members. In other embodiments, the framework 92 can be made from other structures, including the non-limiting example of steel framing members. The construction insert 10 is installed to the hoistway wall 90 in the following manner. First, the brackets 14 and 16 are positioned such that the brackets 14 and 16 are seated on a surface of the framework 92. In this position, the front face 18 of the construction insert 10 is facing away from the hoistway wall 90. Attachment devices 96, such as for example nails, are driven through the plurality of second apertures 42, thereby attaching the construction insert 10 to the framework 92. Once the construction insert 10 is attached to the framework 92, the construction insert 10 can be used as described above.

As discussed above, the construction insert 10 is advantageously configured for installation in elevator hoistways that are constructed of a variety of materials without changing the configuration of the construction insert 10.

The principle and mode of operation of the construction insert has been described in its preferred embodiments. However, it should be noted that the construction insert may be practiced otherwise than as specifically illustrated and described without departing from its scope. 

1. A construction insert configured for use within an elevator hoistway, the construction insert comprising: a channel having a front face and a back face opposing the front face, the channel configured to define an internal passage within the channel; and a plurality of brackets attached to the back face of the channel, each of the brackets configured for attachment to a structure within the elevator hoistway; wherein each of the brackets is planar in shape.
 2. The construction insert of claim 1, wherein the channel includes a slot extending continuously from a first end of the channel to a second end of the channel.
 3. The construction insert of claim 1, wherein the internal passage formed within the channel is adapted to receive the head of a bolt, thereby constraining rotational movement of the bolt relative to the channel.
 4. The construction insert of claim 2, wherein the slot is positioned on the front face of the channel.
 5. The construction insert of claim 1, wherein the internal passage has a rectangular cross-sectional shape.
 6. The construction insert of claim 1, wherein each of the brackets includes a first aperture configured for insertion of a support rod.
 7. The construction insert of claim 1, wherein each of the brackets includes a plurality of second apertures configured for passage of a fastener.
 8. The construction insert of claim 1, wherein each of the brackets extend in a generally perpendicular direction from the back face of the channel.
 9. A construction insert configured for use within an elevator hoistway, the construction insert comprising: a channel having a slot extending continuously from a first end to a second end, the channel having a top face, a bottom face, a front face, and a back face configured to define an internal passage within the channel; and a plurality of brackets attached to the back face of the channel, each of the brackets is configured for attachment to a structure within the elevator hoistway; wherein the internal passage formed within the channel is adapted to receive a head of a bolt, thereby constraining rotational movement of the bolt relative to the channel; wherein each of the brackets is planar in shape.
 10. The construction insert of claim 9, wherein the slot is positioned on the front face of the channel.
 11. The construction insert of claim 9, wherein the internal passage has a rectangular cross-sectional shape.
 12. The construction insert of claim 9, wherein each of the brackets includes a first aperture configured for insertion of a support rod.
 13. The construction insert of claim 9, wherein each of the brackets includes a plurality of second apertures configured for passage of a fastener.
 14. The construction insert of claim 9, wherein each of the brackets extend in a generally perpendicular direction from the back face of the channel.
 15. A construction insert in combination with a bolt, the combination configured for use within an elevator hoistway, the combination of the construction insert and the bolt comprising: a channel having a slot extending continuously from a first end to a second end, the channel having a top face, a bottom face, a front face, and a back face configured to define an internal passage within the channel; and a plurality of brackets attached to the back face of the channel, each of the brackets is configured for attachment to a structure within the elevator hoistway; wherein the internal passage formed within the channel is adapted to receive a head of the bolt, thereby constraining rotational movement of the bolt relative to the channel; wherein each of the brackets is planar in shape.
 16. The construction insert of claim 15, wherein the slot is configured for slidable movement of the bolt from the first end of the channel to the second end of the channel.
 17. A method of securing an object within an elevator hoistway, the method comprising the steps of: providing a construction insert, the construction insert including a channel and a plurality of brackets, the channel having a slot extending continuously from a first end to a second end, the channel having a top face, a bottom face, a front face and a back face configured to define an internal passage within the channel, each of the brackets attached to the back face of the channel, wherein the internal passage formed within the channel is adapted to receive a head of a bolt, thereby constraining rotational movement of the bolt relative to the channel, and wherein the brackets are planar in shape; attaching each of the brackets of the construction insert to a structure within the elevator hoistway such that the front face of the construction insert is facing away from the structure; inserting a head of the bolt into the internal passage of the construction insert such that the bolt extends through the slot; and fastening the object to the bolt.
 18. The method of claim 17, wherein the structure is a poured concrete wall.
 19. The method of claim 18, including the step of inserting a support rod through a first aperture in each of the brackets.
 20. The method of claim 19, including the step of forming a poured concrete wall around the support rod. 